U.S. patent application number 12/844163 was filed with the patent office on 2011-07-21 for composite building and panel systems.
This patent application is currently assigned to PROPST FAMILY LIMITED PARTNERSHIP, LLC. Invention is credited to John Eugene Propst.
Application Number | 20110173911 12/844163 |
Document ID | / |
Family ID | 44276478 |
Filed Date | 2011-07-21 |
United States Patent
Application |
20110173911 |
Kind Code |
A1 |
Propst; John Eugene |
July 21, 2011 |
COMPOSITE BUILDING AND PANEL SYSTEMS
Abstract
A building panel structure is disclosed, in which composite
building panels are used to form a structure. A composite building
panel is disclosed which includes a core and a coating applied over
the core. In some embodiments the core consists of a frame and one
or more than one insulating structural block. The insulating
structural blocks can be encapsulated polystyrene (EPS) foam
blocks. In some embodiments the coating includes an inner scratch
layer and an outer main brown layer. The inner scratch layer can be
formed of at least two layers. The outer main brown layer can
include a fiberglass mesh embedded into the outer main brown layer.
A method of forming a building panel structure is disclosed which
includes forming a core using a frame and one or more than block,
applying an inner scratch layer to the core, and applying an outer
main brown layer over the inner scratch layer.
Inventors: |
Propst; John Eugene;
(Phoenix, AZ) |
Assignee: |
PROPST FAMILY LIMITED PARTNERSHIP,
LLC
Phoenix
AZ
|
Family ID: |
44276478 |
Appl. No.: |
12/844163 |
Filed: |
July 27, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61296616 |
Jan 20, 2010 |
|
|
|
12844163 |
|
|
|
|
Current U.S.
Class: |
52/309.13 ;
156/242; 427/403; 442/1; 52/588.1; 52/794.1 |
Current CPC
Class: |
B32B 5/26 20130101; B32B
3/08 20130101; Y10T 156/10 20150115; B32B 2260/021 20130101; Y10T
29/49629 20150115; B32B 13/14 20130101; B32B 2307/584 20130101;
B32B 2471/00 20130101; E04C 2/243 20130101; B32B 3/06 20130101;
Y10T 442/176 20150401; Y10T 29/49622 20150115; B32B 3/18 20130101;
B32B 5/245 20130101; B32B 2260/044 20130101; B32B 37/18 20130101;
Y10T 442/171 20150401; B32B 2266/0228 20130101; B32B 2419/06
20130101; Y10T 29/49826 20150115; B32B 13/045 20130101; B32B
2260/023 20130101; B32B 2607/02 20130101; E04C 2/296 20130101; B32B
2307/304 20130101; B05D 1/36 20130101; B32B 2262/101 20130101; B32B
2419/00 20130101; Y10T 442/10 20150401; B32B 2307/712 20130101 |
Class at
Publication: |
52/309.13 ;
442/1; 427/403; 156/242; 52/794.1; 52/588.1 |
International
Class: |
E04C 2/34 20060101
E04C002/34; B32B 5/02 20060101 B32B005/02; B05D 1/36 20060101
B05D001/36; B32B 38/00 20060101 B32B038/00; E04C 2/38 20060101
E04C002/38; E04C 2/22 20060101 E04C002/22 |
Claims
1. A building panel comprising: a core having a front surface, a
rear surface, and side surfaces; and a coating covering at least a
portion of the front or rear surfaces, wherein the coating
comprises: an inner scratch layer; and an outer main brown layer,
the outer main brown layer further comprising cement, aggregate,
acrylic bonder, fiberglass strands, and fiberglass mesh.
2. The building panel of claim 1 wherein the inner scratch layer
consists of at least two layers, the layers comprising: a first
scratch layer A consisting essentially of cement, aggregate, and
acrylic bonder; and a second scratch layer B comprising cement,
aggregate, acrylic bonder, fiberglass strands, and fiberglass
mesh.
3. The building panel of claim 1 wherein the inner scratch layer
comprises a wire mesh.
4. The building panel of claim 1 wherein the outer main brown layer
aggregate comprises perlite.
5. The building panel of claim 1 wherein the outer main brown layer
aggregate comprises sand.
6. The building panel of claim 2 wherein the core comprises: a
frame; and one or more than one insulating structural block coupled
to the frame.
7. The building panel of claim 6, wherein the insulating structural
block is composed of expanded polystyrene foam.
8. The building panel of claim 6, wherein the frame is embedded in
the one or more than one insulating structural block.
9. A building panel structure comprising: a building panel with a
building panel groove; and a footer with an integral footer tongue,
wherein the building panel groove is coupled to the footer
tongue.
10. The building panel structure of claim 9 wherein the footer and
the footer tongue are formed of concrete.
11. The building panel structure of claim 10 wherein the building
panel further comprises: a core having a front surface, a rear
surface, and side surfaces; and a coating covering at least a
portion of the front or rear surfaces.
12. The building panel structure of claim 11 further comprising a
track coupled to the core, the track comprising: a base portion
covering a portion of a side; and a rain drain channel formed in
the base portion.
13. The building panel structure of claim 12 wherein the track
further comprises a seal spacer channel.
14. The building panel structure of claim 13 wherein the track
further comprises a screed boundary.
15. The building panel structure of claim 14 wherein the core
comprises: a frame; and one or more than one insulating structural
block coupled to the frame.
16. The building panel structure of claim 15, wherein the coating
comprises: an inner scratch layer comprising: a first scratch layer
A consisting essentially of cement, aggregate, and acrylic bonder;
and a second scratch layer B comprising cement, aggregate, acrylic
bonder, fiberglass strands, and fiberglass mesh; and an outer main
brown layer, the outer main brown layer comprising cement,
aggregate, acrylic bonder, fiberglass strands, and fiberglass
mesh.
17. A method of forming a building panel structure comprising:
forming a core using a frame and one or more than one insulating
structural block; applying an inner scratch layer to a portion of
the core; and applying an outer main brown layer over the inner
scratch layer, the outer main brown layer comprising cement,
aggregate, acrylic bonder, fiberglass strands, and fiberglass
mesh.
18. The method of claim 17 wherein applying an inner scratch layer
to a portion of the core further comprises: creating a first
scratch layer A mixture comprising cement, aggregate, acrylic
bonder, and water; blowing the first scratch layer A mixture onto a
portion of the core; allowing the first scratch layer A mixture to
cure; creating a second scratch layer B brown mixture comprising
cement, aggregate, acrylic bonder, fiberglass strands, and water;
trowelling the second scratch layer B brown mixture over the first
scratch layer A; embedding a fiberglass mesh in the second scratch
layer B brown mixture while the second scratch layer B brown
mixture is still wet; and allowing the second scratch layer B brown
mixture to cure.
19. The method of claim 17 wherein applying an outer main brown
layer over the inner scratch layer further comprises: creating a
main brown layer brown mixture comprising cement, aggregate,
acrylic bonder, fiberglass strands, and water; trowelling the main
brown layer brown mixture over the inner scratch layer; embedding a
fiberglass mesh in the main brown layer brown mixture while the
main brown layer brown mixture is still wet; and allowing the main
brown layer brown mixture to cure.
20. The method of claim 19 wherein the main brown layer brown
mixture aggregate comprises 20 grit sand and 30 grit sand.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application to John Propst entitled "Layered Building Panel
System," Ser. No. 61/296,616, filed Jan. 20, 2010, the disclosure
of which is hereby incorporated entirely herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention relates generally to materials for
constructing buildings and structures and more specifically to
composite building panels.
[0004] 2. State of the Art
[0005] Buildings have historically been constructed of brick,
cement block, wood frame and, more recently, steel frame and
stucco. The material and techniques used in constructing buildings
is evolving in an effort to reduce cost, increase energy
efficiency, reduce the amount of wood usage in buildings, and to
reduce material waste. Cement block and brick construction requires
a large amount of manpower to create a building, which raises the
cost of the building. Wood has long been a staple material in
building construction, but recently there is a desire to preserve
forest resources. Wood is inherently more susceptible to damage
from inclement weather, moisture, mold, fire, and insect
infestation. Also, when wood is used to create a building there can
be a large amount of waste. This is because standard sized boards
are sent to the construction site, which must be cut and assembled
at the building site into a building. The labor involved in cutting
lumber to size results in high labor costs and a large amount of
lumber wasted from boards cut to size.
[0006] It is also desirable to increase the energy efficiency of
buildings in order to reduce the energy costs during the lifetime
of the building. Cement block, brick, and wood frame and stucco
construction do not provide the high level of energy efficiency
that can be obtained from newer materials.
[0007] Foam blocks have become a popular alternative and are
environmentally sustainable as compared to traditional wood, cement
block, and brick construction materials. Foam block systems are
lightweight, can be molded or formed into any needed shape, result
in a thermally efficient building construction, and require less
skilled manpower to form into a building structure. Other benefits
include, but are not limited to, a resistance to moisture, mold,
fire and insect damage. The foam blocks are constructed using
materials which are recyclable and renewable, provide good
insulating qualities, and are often themselves made from recycled
materials. Alternatively, construction blocks can also be made from
other environmentally friendly materials such as straw, wood
fibers, paper, and glass, for example.
[0008] One problem with some of the new building materials such as
foam block is that the structural strength of a building element
such as a wall may not be as high as when wood, brick or cement
block are used to form the building element. This can be
particularly important in areas where buildings are required to
withstand high winds or earthquakes. There is a need for a
prefabricated building panel system which minimizes construction
time, uses environmentally friendly materials, and results in a
building panel with high structural strength and structural
integrity.
DISCLOSURE OF THE INVENTION
[0009] This invention relates generally to materials for
constructing buildings and structures and more specifically to
composite building panels. Disclosed is a composite building panel
comprising a core and a coating covering a portion of the core. The
core includes a front surface, a rear surface, and one or more than
one side. The coating includes an inner scratch layer and an outer
main brown layer. The outer main brown layer includes cement,
aggregate, acrylic bonder, fiberglass strands, and fiberglass mesh.
In some embodiments the scratch layer consists of at least two
layers. In some embodiments the scratch layer includes a first
scratch layer A of cement, aggregate, and acrylic bonder, and a
second scratch layer B which includes cement, aggregate, acrylic
bonder, fiberglass strands, and fiberglass mesh. In some
embodiments the inner scratch layer includes a wire mesh. In some
embodiments the outer main brown layer aggregate includes perlite.
In some embodiments the outer main brown layer aggregate includes
sand. In some embodiments the core includes a frame and one or more
than one insulating structural block coupled to the frame. In some
embodiments the insulating structural block is composed of expanded
polystyrene foam. In some embodiments the frame is embedded in the
one or more than one insulating structural block. In some
embodiments the building panel includes a control joint.
[0010] A composite building panel structure is disclosed which
includes a composite building panel with a building panel groove,
and a footer with an integral footer tongue. The building panel
groove is coupled to the footer tongue to create a composite
building panel structure. In some embodiments the footer and the
footer tongue are both formed of concrete. In some embodiments the
building panel includes a core and a coating covering a portion of
the core. In some embodiments the core has a front surface, a rear
surface and one or more than one sides. In some embodiments the
building panel structure includes a track coupled to the core,
where the track comprises a base portion covering a portion of a
side, and a rain drain channel formed in the base portion. In some
embodiments the track further comprises a seal spacer channel. In
some embodiments the track comprises a screed boundary. In some
embodiments the core includes a frame and one or more than one
insulating structural block coupled to the frame. In some
embodiments the coating includes an inner scratch layer and an
outer main brown layer. The inner scratch layer in some embodiments
includes a first scratch layer A of cement, aggregate, and acrylic
bonder, and a second scratch layer B of cement, aggregate, acrylic
bonder, fiberglass strands, and fiberglass mesh. The outer main
brown layer includes cement, aggregate, acrylic bonder, fiberglass
strands, and fiberglass mesh.
[0011] A building panel is disclosed which includes a core with a
front surface, a rear surface, and one or more than one side; and a
track coupled to the core. The track includes a base portion which
covers a portion of the edge, and a rain drain channel formed in
the base portion. In some embodiments the track further comprises a
seal spacer channel. In some embodiments the track further
comprises a screed boundary. In some embodiments the track further
comprises a first and a second opposing arm extending from the
base, where the first and second opposing arm frictionably engage
the front surface and the rear surface, respectively, of the
core.
[0012] A method of forming a building panel structure is disclosed
including forming a core using a frame and one or more than one
insulating structural block, applying an inner scratch layer to a
portion of the core, and applying an outer main brown layer over
the inner scratch layer. The outer main brown layer is made of
cement, aggregate, acrylic bonder, fiberglass strands, and
fiberglass mesh. In some embodiments forming a core using a frame
and one or more than one insulating structural block means
embedding the frame within the one or more than one insulating
structural block.
[0013] In some embodiments applying an inner scratch layer to a
portion of the core includes additional steps. In some embodiments
applying an inner scratch layer to a portion of the core includes
creating a first scratch layer A mixture comprising cement,
aggregate, acrylic bonder, and water. In some embodiments applying
an inner scratch layer to a portion of the core includes blowing
the first scratch layer A onto a portion of the core. In some
embodiments applying an inner scratch layer to a portion of the
core includes allowing the first scratch layer A to cure. In some
embodiments applying an inner scratch layer to a portion of the
core includes creating a second scratch layer B brown mixture
comprising cement, aggregate, acrylic bonder, fiberglass strands,
and water. In some embodiments applying an inner scratch layer to a
portion of the core includes trowelling the second scratch layer B
brown mixture over the first scratch layer A. In some embodiments
applying an inner scratch layer to a portion of the core includes
embedding a fiberglass mesh in the second scratch layer B brown
mixture while the second scratch layer B brown mixture is still
wet. In some embodiments applying an inner scratch layer to a
portion of the core includes allowing the second scratch layer B
brown mixture to cure.
[0014] In some embodiments applying an outer main brown layer over
the inner scratch layer includes additional steps. In some
embodiments applying an outer main brown layer over the inner
scratch layer includes creating a main brown layer brown mixture
comprising cement, aggregate, acrylic bonder, fiberglass strands,
and water. In some embodiments applying an outer main brown layer
over the inner scratch layer includes trowelling the main brown
layer brown mixture over the inner scratch layer. In some
embodiments applying an outer main brown layer over the inner
scratch layer includes embedding a fiberglass mesh in the main
brown layer brown mixture while the main brown layer brown mixture
is still wet. In some embodiments applying an outer main brown
layer over the inner scratch layer includes allowing the main brown
layer brown mixture to cure. In some embodiments the main brown
layer brown mixture aggregate includes 20 grit sand and 30 grit
sand. In some embodiments the main brown layer brown mixture
aggregate include perlite. In some embodiments the main brown layer
brown mixture aggregate includes vermiculite.
[0015] In some embodiments applying an inner scratch layer further
includes embedding a wire mesh in the inner scratch layer. In some
embodiments the method of forming a building panel structure
further includes pouring a footer with an integral footer tongue,
and coupling the core to the footer tongue, wherein the core
includes a building panel groove.
[0016] A method of forming a structure is disclosed which includes
forming a building panel, coupling a track to the building panel,
where the track includes a rain drain channel, and interconnecting
multiple building panels to create a structure. In some embodiments
forming a building panel includes forming a core with a frame and
one or more than one insulating structural block, and applying a
coating to a portion of the core. In some embodiments applying a
coating to a portion of the core includes applying an inner scratch
layer to a portion of the core. In some embodiments applying an
inner scratch layer to a portion of the core includes applying an
inner scratch layer A onto a portion of the core, and applying an
outer scratch layer B over the inner scratch layer A. In some
embodiments the inner scratch layer A includes cement, aggregate,
and acrylic bonder. In some embodiments the outer scratch layer B
includes cement, aggregate, acrylic bonder, fiberglass strands, and
fiberglass mesh. In some embodiments applying an inner scratch
layer further includes embedding a wire mesh in the inner scratch
layer. In some embodiments applying a coating to a portion of the
core includes applying an outer main brown layer to a portion of
the core, where the outer main brown layer includes cement,
aggregate, acrylic bonder, fiberglass strands, and fiberglass mesh.
In some embodiments the method of forming a structure includes
coupling a track to a footer. In some embodiments interconnecting
multiple building panels includes coupling a first building panel
track to a second building panel track.
[0017] The foregoing and other features and advantages of the
present invention will be apparent from the following more detailed
description of the particular embodiments of the invention, and as
illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of one embodiment of composite
building panel 112 according to the invention.
[0019] FIG. 2 is a perspective view of core 158 of building panel
112 of FIG. 1.
[0020] FIG. 3 is a perspective view of one embodiment of insulating
structural block 140 that can be used with building panel 112
according to the invention.
[0021] FIG. 4 is a perspective view of another embodiment of
insulating structural block 140 that can be used with building
panel 112 according to the invention, with insulating structural
block 140 of FIG. 4 having interlocking features 150.
[0022] FIG. 5 is a top view of two interlocked insulating
structural blocks 140 of building panel 112 of FIG. 1, with
insulating structural blocks 140 having interlocking features
150.
[0023] FIG. 6 shows a perspective view of core 158 with coating 160
applied, creating building panel 112 of building panel structure
110 according to the invention.
[0024] FIG. 7 shows horizontal cross-section 7-7 of building panel
112 of FIG. 6.
[0025] FIG. 8 shows vertical cross-section 8-8 of building panel
112 of FIG. 6.
[0026] FIG. 9 shows a close-up cross-section of coating 160 taken
at section 9 of FIG. 8.
[0027] FIG. 10 is a horizontal cross-section of an embodiment of
building panel 112 according to the invention, with building panel
112 including wire mesh 272 embedded in core 158.
[0028] FIG. 11 is a horizontal cross-section of another embodiment
of building panel 112 according to the invention, with building
panel 112 including wire mesh 272 embedded in core 158.
[0029] FIG. 12 shows a vertical cross section of an embodiment of
building panel 112, with building panel 112 including C-channel 136
embedded in insulating structural block tongue 152 of core 158.
[0030] FIG. 13 shows an embodiment of building panel structure 110
where building panel 112 includes an additional embodiment of
building panel tongue 154 and footer 190 includes an additional
embodiment of footer tongue 194.
[0031] FIG. 14 is a horizontal cross-section of an embodiment of
building panel 112 according to the invention using control joint
142 according to the invention.
[0032] FIG. 15 is a horizontal cross-section of an embodiment of
building panel 112 according to the invention with an additional
embodiment of control joint 142 according to the invention.
[0033] FIG. 16 is a perspective view of an embodiment of building
panel 212 according to the invention.
[0034] FIG. 17 is a perspective view of core 258 of building panel
212 of FIG. 14.
[0035] FIG. 18 is an end view of track 228 used with building panel
212 of FIG. 14.
[0036] FIG. 19 is a perspective view of track 228 used with
building panel 212 of FIG. 14.
[0037] FIG. 20 is a horizontal cross section of building panel 212
of FIG. 14, using core 258 and coating 260.
[0038] FIG. 21 is a vertical cross section of building panel 212 of
FIG. 14, using core 258 and coating 260.
[0039] FIG. 22 shows a cross-section of two building panels 212
connected track-to-track according to the invention.
[0040] FIG. 23 shows a cross-section of building panel 212
connected to concrete foundation 192 according to the
invention.
[0041] FIG. 24 is a perspective view of building panel 312
according to the invention.
[0042] FIG. 25 is a perspective view of core 358 of building panel
312 of FIG. 22.
[0043] FIG. 26 is a horizontal cross-section of building panel 312
of FIG. 22.
[0044] FIG. 27 is a vertical cross-section of building panel 312 of
FIG. 22.
[0045] FIG. 28 illustrates method 400 of forming a building panel
structure according to the invention.
[0046] FIG. 29 illustrates method 440 of forming a structure
according to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0047] As discussed above, embodiments of the present invention
relate to material used in constructing buildings and more
specifically to composite building panels and composite building
panel structures.
[0048] The use of environmentally friendly, insulating, lightweight
block materials for use as the walls, roofs, floors and other
structures in buildings is increasing in popularity. The blocks of
material are being used to replace concrete blocks and insulated
wood and stucco walls. These blocks are structural elements which
provide insulation properties and a shaped mass which defines the
shape of the structure to be built. Expanded polystyrene (EPS) foam
blocks are a popular material, but other materials such as straw,
plastic, and recycled elements are also being used to create
insulating structural blocks. These new building materials use less
wood, decrease construction waste, often use recycled materials,
and create a building which is more energy efficient than standard
wood frame and plaster construction buildings. Insulating
structural blocks such as EPS foam blocks are often lightweight and
can be molded or shaped easily to create any desired shape. These
new block materials, including EPS foam blocks, sometimes do not
posses the necessary structural strength for specific building
structures. In these cases it is necessary to add structural
elements to the building panels made from insulating structural
block materials. Disclosed herein are composite building panels and
methods of creating composite building panels using insulating
structural blocks, frames, and coatings over the blocks and frames
to create structurally strong structures and building panels, while
still retaining the lightweight, environmentally friendly, and
energy efficient characteristics of the insulating structural
blocks.
[0049] FIG. 1 shows a perspective view of one embodiment of a
composite building panel according to the invention. A composite
building panel means a building panel (a building element) formed
of multiple components, which is used in constructing a form,
structure, building, or edifice. Composite building panel 112 is
shown including core 158 and coating 160 covering a portion of core
158. Composite building panel 112 is used to form walls, floors,
ceilings, beams, or other elements used in creating a structure,
edifice, or building.
[0050] Composite building panel (also referred to as building panel
or just panel) 112 is shown in FIG. 1 as having a rectangular shape
for use as a wall or block fence structure, for example. Building
panel 112 can be formed in any size and shape according to the
needs of the structure to be built. In some embodiments building
panel 112 is square, or rectangular or round, or oval, oblong or
elongated. Building panel 112 can be curved, or part curved and
part rectangular. Building panel 112 can take any shape. Building
panel 112 takes a shape according to the shape of the structure to
be built. Core 158 forms the basic shape, and coating 160 covers a
portion of core 158 to add strength to building panel 112, to form
an impermeable layer on a portion of core 158, and/or to provide an
aesthetically pleasing surface for exterior finishing. Building
panel 112 has first surface 114 which includes coating 160, and
second surface 116 which includes coating 160. Coating 160 will be
discussed in detail shortly.
[0051] FIG. 2 is a perspective view of core 158 of building panel
112 of FIG. 1. Building panel 112 is formed of core 158 and coating
160, where coating 160 covers a portion of core 158. Core 158 has
front surface 124, rear surface 126, and multiple sides 180 (two of
four sides 180 shown) as shown in FIG. 2. Coating 160 according to
the invention covers at least a portion of front surface 124 or
rear surface 126 of core 158. In this embodiment coating 160 covers
both front surface 124 and rear surface 126. Core 158 is formed in
this embodiment of frame 130 and one or more than one insulating
structural block 140, as shown in FIG. 2 through FIG. 5. In this
embodiment core 158 includes more than one insulating structural
block 140. In some embodiments core 158 includes one insulating
structural block 140. FIG. 3 is a perspective view of an insulating
structural block 140 that can be used in building panel 112
according to the invention. FIG. 4 is a perspective view of another
insulating structural block 140 that can be used in composite
building panel 112 according to the invention. In FIG. 4 insulating
structural block 140 includes interlock elements 150. Interlock
elements 150 are used to interlock multiple insulating structural
blocks 140 to each other and to interlock insulating structural
blocks 140 to frame 130. FIG. 5 is a top view of two interlocked
insulating structural blocks 140 of building panel 112 of FIG. 1,
with interlocking features 150 which interlock insulating
structural blocks 140 and frame 130 as detailed in FIG. 6 through
FIG. 8.
[0052] In some embodiments of building panel 112 core 158 is made
solely of insulating structural blocks 140. In some embodiments
core 158 is made of insulating structural blocks 140 and frame 130,
as shown in FIG. 2. In some embodiments core 158 is made of other
elements besides insulating structural blocks 140 and frame 130.
Core 158 can be formed of any material or materials that provide
the necessary building-shaped elements and that accepts coating 160
to create building panel 112 according to the invention. Insulating
structural blocks are also referred to in this document as simply
"blocks".
[0053] Frame 130 in this embodiment creates the skeletal structure
for the walls, floors, ceiling, beams, or other building elements
that are needed to form a structure using building panel 112. Frame
130 in the embodiment shown in FIG. 2 includes vertical members 132
and horizontal members 134. In this embodiment frame 130 is formed
of galvanized steel. Frame 130 according to the invention can be
made of other structural material such as wood, aluminum, other
metals, plastic, etc. In this embodiment frame 130 is formed from
4''.times.4''.times. 3/16'' galvanized steel box tubing. Horizontal
members 134 and vertical members 132 are coupled in a manner which
holds the members together solidly. In some embodiments mechanical
attachments such as bolts are used. In some embodiments the members
of frame 130 are welded together. In some embodiments the
individual members of frame 130 connect together at angles other
than horizontal and vertical. Diagonal frame members are used in
some embodiments of frame 130. In some embodiments frame 230
includes metal straps running diagonally. It is to be understood
that frame 130 according to the invention can take many different
shapes and sizes according to the specifics of the structure to be
built. Frame 130 can be formed of many different materials
according to the structural strength needed by the structure to be
built.
[0054] Frame 130 in this embodiment is embedded in insulating
structural blocks 140. Frame 130 being embedded in blocks 140 means
that the majority of frame 130 is encased in blocks 140, with a
minimum of surface area of frame 130 not covered by blocks 140.
Frame 130 is embedded in insulating structural blocks 140 by
cutting blocks 140 into shapes that will encircle and couple to
frame 130. Having frame 130 embedded in insulating structural
blocks 140 provides several advantages for building panel 112.
Frame 130 being embedded in blocks 140 provides structural strength
to core 158 and yet leaves most of the outer surface of core 158 as
a surface of blocks 140, so that the outer surface of core 158 can
be easily shaped and covered with coating 160. This allows core 158
and building panel 112 to be shaped for aesthetically pleasing
shapes, and provides a surface which accepts and retains coating
160 for strength and exterior finishing. In this embodiment, where
frame 130 is embedded in blocks 140, there are portions of frame
130 which are not covered by block 140 so that frame 130 can be
connected to other frames and structures, but the majority of frame
130 is embedded in blocks 140. In other embodiments of building
panel 112 frame 130 is not embedded in blocks 130, meaning that
significant portions of frame 130 are on the exterior surface of
core 158. Some of these embodiments will be discussed later in this
document.
[0055] Insulating structural blocks 140 have several purposes,
including defining the shape of the building panel 112 being
created, providing insulating properties, and providing a surface
for applying coating 160 or other coatings or layers. Insulating
structural blocks 140 in core 158 of FIG. 2 are used to enclose
frame 130 elements and to form the desired shape of the structure
to be built with building panel 112. Some embodiments of insulating
structural blocks 140 according to the invention are shown in FIG.
3, FIG. 4 and FIG. 5. Blocks 140 are often formed to interlock with
each other and with frame 130 as shown in FIG. 2, FIG. 4, and FIG.
5. In this embodiment insulating structural blocks 140 according to
the invention are made of expanded polystyrene (EPS) foam, creating
an EPS foam insulating structural block 140. EPS foam blocks
provide high energy efficiency and are lightweight. EPS foam can be
created from recycled materials and can itself be recycled. Another
desirable feature of EPS foam block 140 is that it can be easily
molded or cut into any desired shape. FIG. 4 and FIG. 5 shows EPS
foam insulating structural blocks 140 that have been cut to include
interlock elements 150, where interlock elements 150 in this
embodiment include tongue 152 and groove 154. Blocks 140 can be
made into any shape, size, and structure according to the structure
being built using building panel 112. In this embodiment insulating
structural blocks 140 are 4'.times.8'.times.6'' EPS foam insulating
structural blocks, which have interlocking elements 150 cut into
them so that they interlock with themselves and with frame 130 to
create core 158 as shown in FIG. 2. In this embodiment one pound
density EPS foam is used but any suitable material and density can
be used according to the invention which provides suitable
structural characteristics. Blocks 140 are connected to each other
and to concrete in this embodiment using a polymer-based acrylic
adhesive 156 such as Primus sold by Dryvit Systems Inc. (Dryvit).
Blocks 140 are coupled to metal or wood in this embodiment using a
water-based acrylic copolymer adhesive such as Adhesive for EPS
(ADEPS) from Dryvit. In some embodiments insulating structural
blocks 140 and frame 130 are coupled to other members and to each
other using different adhesives, glues, mechanical attachments, or
other suitable coupling means.
[0056] In this embodiment insulating structural block 140 is made
of EPS foam. Insulating structural block 140 according to the
invention can be made of other materials, including but not limited
to straw, wood, plastic, paper, or recycled materials.
[0057] In the embodiment of core 158 of FIG. 2, insulating
structural block 140 is cut to shape from the rectangular EPS foam
blocks 140 as shown in FIG. 3 to create the shaped insulating
structural blocks 140 as shown in FIG. 4. Cutouts and interlocking
elements are cut from blocks 140 to create a block 140 shape that
will enclose frame 130, interlock with other blocks 140 and frame
130, and provide a surface of the desired shape for the structure
to be built. Blocks 140 according to the invention can be molded to
shape or formed to the correct size and shape using methods such as
slicing, melting, or other block-shaping methods. Block 140 can be
formed to any size and shape needed to create the structure being
formed, such as walls, floors, roofs, ceilings, beams, fences,
bridges, edifices, offices, etc. Blocks 140 and frame 130 can be
formed into any size and shape to create core 158 and building
panel 112 in any size and shape to form the desired structure.
[0058] Openings and passageways for utilities, air flow, or other
types of access through building panel 112 can be easily cut into
core 158 as desired. Openings for windows and doors can be formed
in core 158.
[0059] Coating 160 covers a portion of core 158 to create composite
building panel 112 of composite building panel structure 110 as
shown in FIG. 1 and FIG. 6 through FIG. 9. Coating 160 creates an
outer surface on building panel 112 that is ready to accept
exterior or interior finishing as desired and also contributes to
the strength of building panel 112. FIG. 6 shows a perspective view
of core 158 with coating 160 applied, creating building panel
structure 110 including building panel 112 according to the
invention. FIG. 7 shows horizontal cross section 7-7 of building
panel 112 of FIG. 6. FIG. 8 shows vertical cross section 8-8 of
building panel 112 of building structure 110 of FIG. 6. FIG. 9
shows a close-up cross-section of coating 160 taken at section 9 of
FIG. 8.
[0060] Coating 160 covers a portion of core 158. Coating 160 can
cover a portion of core 158 for many different reasons. Coating 160
can cover a portion of core 158 to add strength to core 158.
Coating 160 can cover a portion of core 158 to provide an
aesthetically pleasing surface finish. Coating 160 can cover a
portion of core 158 to provide a surface for accepting finish
treatments such as paint, stucco, or other exterior finish
treatments. Coating 160 can cover a portion of core 158 to create a
layer of material which protects core 158 from weather, moisture,
and other deteriorating elements. In some embodiments coating 160
covers exterior surfaces. In some embodiments coating 160 covers
interior surfaces. In some embodiments coating 160 covers edge
surfaces. Coating 160 can cover any surface of core 158 or a
portion of any surface of core 158. In the embodiment shown in FIG.
1 through FIG. 9 coating 160 covers front surface 124 of core 158
to create first surface 114 of building panel 112. And in the
embodiment shown in FIG. 1 through FIG. 9 coating 160 covers rear
surface 126 of core 158 to create second surface 116 of building
panel 112. In this way building panel 112 includes core 158 and
coating 160 covering at least a portion of core 158. In this way
building panel 112 includes core 158 and coating 160 covering at
least a portion of front surface 124 or rear surface 126 of core
158.
[0061] Coating 160 in this embodiment is formed of multiple layers
as shown in FIG. 9. In this embodiment coating 160 forms an acrylic
modified cementitious membrane which provides structural strength
to building panel 112 as well as providing a layer impervious to
water and weather, and a layer that is ready to accept final
exterior or interior finishes such as paint, stucco, or other
finishes. In some embodiments coating 160 is formed of a single
layer. In some embodiments coating 160 contains multiple layers. In
this embodiment coating 160 is formed of inner scratch layer 162
and outer main brown layer 166. A scratch layer is a layer that
adheres well to core 158 and provides a base for further layers,
such as outer main brown layer 166, to adhere to. Inner scratch
layer 162 is a cementitious mixture that can be formed from many
different components. In some embodiments inner scratch layer 162
is formed of cement, aggregate, and an acrylic bonder. In some
embodiments inner scratch layer 162 includes a wire mesh embedded
in the cementitious mixture. In some embodiments inner scratch
layer 162 is formed of other components. Further embodiments of
inner scratch layer 162 will be discussed shortly.
[0062] Outer main brown layer 166 is formed of brown mixture 168
and fiberglass mesh 170 embedded in brown mixture 168 while brown
mixture 168 is still wet. Brown mixture 168 is a cementitious
mixture made of cement, aggregate, acrylic bonder, and fiberglass
strands. Brown mixture 168 components are mixed together with water
to form a cementitious mixture, and applied over inner scratch
layer 162. Often brown mixture 168 is trowelled onto inner scratch
layer 162. Fiberglass mesh 170 is embedded in brown mixture 168
while it is still wet. In this way building panel 112 includes core
158, and coating 160 covering a portion of core 158, where coating
160 includes inner scratch layer 162 and outer main brown layer
166. Outer main brown layer 166 includes brown mixture 168
comprising cement, aggregate, acrylic bonder, and fiberglass
strands; and fiberglass mesh 170. In some embodiments the aggregate
in brown mixture 168 includes sand. In some embodiments the
aggregate in brown mixture 168 includes perlite. In some
embodiments the aggregate in brown mixture 168 includes
vermiculite. Perlite and vermiculite improve the fire-resistant
qualities of building panel 112. Therefore perlite and/or
vermiculite are used as aggregate in situations where a building
panel structure 110 or a building panel 112 is required to possess
stringent fire-resistant capabilities. In a particular embodiment
brown mixture 168 is made by mixing together:
[0063] 90 pounds of Portland cement (type 1 and 2)
[0064] 90 pounds of 20 grit silica sand
[0065] 90 pounds of 30 grit silica sand
[0066] 11/2 gallons of acrylic bonder, such as AC-100 from
Dryvit
[0067] 3 pounds of 3/4'' fiberglass strands
[0068] 21/2 gallons of potable water.
In this embodiment the brown mixture 168 aggregate is made of two
sizes of sand, 20 grit sand and 30 grit sand. It is to be
understood that larger or smaller batches can be made by increasing
or decreasing the ingredient measurements proportionately.
Fiberglass mesh 170 is embedded into brown mixture 168 as brown
mixture 168 is applied to inner scratch layer 162 and while brown
mixture 168 is still wet. This mixture has been found to provide
superior structural integrity, water and weather protection, and a
surface optimum for applying further finish coatings if desired. It
is to be understood that brown mixture 168 can be made from other
ingredients for specific structural uses.
[0069] Inner scratch layer 162 can be formed of many different
components. In some embodiments inner scratch layer 162 is a
cementitious mixture applied over a wire mesh. In some embodiments
inner scratch layer 162 is made up of multiple layers. In the
embodiments shown in FIG. 1 through FIG. 9, inner scratch layer 162
is formed of two layers, first scratch layer A 164 and second
scratch layer B 163. First scratch layer A 164 is a "dash" scratch
coat which in this embodiment is machine sprayed onto core 158. In
some embodiments first scratch layer A 164 is applied using other
means. First scratch layer A 164 is a cementitious mixture made of
cement, aggregate, and acrylic bonder. In some embodiments the
aggregate includes sand. In some embodiments the aggregate includes
perlite. In some embodiments the aggregate includes vermiculite. In
a specific embodiment first scratch layer A 164 is formed by mixing
together:
[0070] 90 pounds of Portland cement (type 1 and 2)
[0071] 90 pounds of 20 grit silica sand
[0072] 90 pounds of 30 grit silica sand
[0073] 21/2 gallons of acrylic bonder, such as AC-100 from
Dryvit.
[0074] 21/2 gallons of potable water.
In this embodiment the first scratch layer A 164 aggregate is made
of two sizes of sand, 20 grit sand and 30 grit sand. This first
scratch layer A 164 mixture has been found to adhere well to EPS
foam block and provide a superior surface for accepting further
layers of coating 160. It is to be understood that larger or
smaller amounts of first scratch layer A 164 can be made by
proportionately increasing or decreasing the ingredients. In some
embodiments first scratch layer A 164 has other ingredients and
proportions. Usually first scratch layer A 164 is allowed to cure
(dry) before adding other layers.
[0075] Second scratch layer B 163 is formed of brown mixture 165
and fiberglass mesh 170. Fiberglass mesh 170 is embedded in brown
mixture 165 while brown mixture 165 is being trowelled or otherwise
applied to first scratch layer A 164 and while brown mixture 165 is
still wet. Brown mixture 165 can be trowelled onto the surface of
first scratch layer A 164 or applied by any other means which will
allow brown mixture 165 to cover first scratch layer A and mesh 170
to be embedded into brown mixture 165.
[0076] Brown mixture 165 is a cementitious mixture made of cement,
aggregate, acrylic bonder, and fiberglass strands. Brown mixture
165 components are mixed together with water to form a cementitious
mixture, and applied to first scratch layer A 164 after first
scratch layer A has cured. In some embodiments the aggregate in
brown mixture 165 includes sand. In some embodiments the aggregate
in brown mixture 165 includes perlite. In some embodiments the
aggregate in brown mixture 165 includes vermiculite. In a
particular embodiment brown mixture 165 is made by mixing
together:
[0077] 90 pounds of Portland cement (type 1 and 2)
[0078] 90 pounds of 20 grit silica sand
[0079] 90 pounds of 30 grit silica sand
[0080] 11/2 gallons of acrylic bonder, such as AC-100 from
Dryvit
[0081] 3 pounds of 3/4'' fiberglass strands
[0082] 21/2 gallons of potable water.
In this embodiment the brown mixture 165 aggregate is made of two
sizes of sand, 20 grit sand and 30 grit sand. It is to be
understood that larger or smaller batches can be made by increasing
or decreasing the ingredient measurements proportionately.
Fiberglass mesh 170 is embedded into brown mixture 165 while brown
mixture 165 is still wet. This mixture has been found to provide
superior structural integrity, water and weather protection, and a
surface optimum for applying outer main brown layer 166. It is to
be understood that brown mixture 165 can be made from other
ingredients for specific structural uses. Usually second scratch
layer B 163 is allowed to cure before adding other layers on
top.
[0083] Coating 160, inner scratch layer 162, and outer main brown
layer 166 can be made with many different thicknesses, depending on
the specific use of building panel 112 and the structural strength
needed. In some embodiments additional layers of inner scratch
layer 162 and/or outer main brown layer 166 are added for
additional strength. In some embodiments other layers are added. It
is to be understood that finishing coatings are often applied to
coating 160. These finishing coatings are applied for differing
interior and exterior surface aesthetics and include paint, stucco,
and other finishing layers and coatings.
[0084] In the embodiment shown in FIG. 9 inner scratch layer 162 is
formed to be about 1/8'' thick. Outer main brown layer 166 is
formed to be about 1/4'' thick. When these layers cure, coating 160
provides a smooth surface for applying finish coatings, and is
structurally very strong, energy efficient, and lightweight.
Composite building panel 112 with core 158 and coating 160 has
greater flex strength and shear strength than other block panels
due to the structured composite layers of core 158 and coating 160.
This specific embodiment is used for walls, roofs, and beams of
buildings and structure. Additional layers and other thicknesses
can be used according to the invention for building panel 112 to
achieve different panel strengths and uses.
[0085] In some embodiments control joints are cut into core 158
before coating 160 is applied. Embodiments of building panel 112
with control joints 142 are shown in FIG. 14 and FIG. 15 and will
be discussed shortly. Holes and openings for windows and doors,
access channels, and passageways for facilities and air handling
can be cut into core 158 to create building panel 112 of a size and
shape for the structure to be built. Core 158 and coating 160 can
be easily formed into any size and shape structure, resulting in a
lightweight, energy efficient, strong building panel 112.
[0086] FIG. 6 through FIG. 8 shows composite building panel
structure 110 according to the invention, including building panel
112. A composite building panel structure is any structure built
using one or more than one composite building panel as an element
in the structure. Building panel structure 110 in this embodiment
includes building panel 112 and footer 190, as shown in FIG. 6 and
FIG. 8. Building panel 112 has building panel interlock element
154, which in this embodiment is building panel groove 154. Footer
190 has integral footer interlock element 194, which in this
embodiment is footer tongue 194. Footer tongue 194 couples with
building panel groove 154 to couple building panel 112 to footer
190. Footer interlock element 194 is integral to footer 190 because
footer tongue 194 and footer 190 are one integral piece. In this
embodiment footer 190 and footer tongue 194 are both made of
concrete. Footer tongue 194 is poured together with footer 190 so
that footer 190 and footer tongue 194 are one integral piece.
Footer tongue 194 not only provides a coupling for building panel
112, footer tongue 194 also stops moisture, water, weather, and
other elements from penetrating the interface between building
panel 112 and footer tongue 194. In some embodiments footer 190 and
footer tongue 194 are poured along the exterior edge of a
structure. After building panels 112 are coupled to footer 190 to
create building structure 110, even if water, moisture, or other
elements penetrate the outer interface between building panel 112
and footer 190, they cannot "climb" footer tongue 194 to get to the
other side of building panel 112. In this way integral footer
tongue 194 provides moisture and weather protection for building
panel structure 110.
[0087] Building panel interlock element 154 can take many different
forms. In some embodiments building panel interlock element 154 is
a building panel tongue. In some embodiments building panel
interlock element 154 has a form other than a tongue or a groove.
In some embodiments building panel groove 154 or footer tongue 194
have barbs, spikes, hooks or other surface effects which help to
hold footer tongue 194 in building panel groove 154.
[0088] Footer interlock element 194 can take many different forms.
In some embodiments footer interlock element 154 is a footer
groove. In some embodiments footer interlock element 194 takes a
form other than a tongue or a groove.
[0089] In the embodiment shown in FIG. 6 through FIG. 8, building
panel structure 110 is constructed by first pouring concrete footer
190, including integral footer tongue 194, as a single pour. In
some embodiments footer 190 is poured in multiple pours. Footer 190
and footer tongue 194 are formed using any method which results in
footer 190 and footer tongue 194 being one integral concrete piece.
Concrete foundation 192 is often poured next. Building panel 112 is
coupled to footer 190 using footer tongue 194 and building panel
groove 154. Building panel 112 can be constructed and coupled to
footer 190 in many different ways. In this embodiments building
panel 112 is constructed on-site and on footer 190. Core 158 is
built on footer 190 and connected to footer 190. In this embodiment
frame 130 is built and connected to footer 190 using bolts 188 as
shown in FIG. 6. Shaped blocks 140 of core 158 are coupled to frame
130, to each other, and to footer tongue 194 to create core 158
coupled to footer 190 using footer tongue 194 and building panel
groove 154. Coating 160 is applied to a portion of core 158. In
this embodiment coating 160 is applied to front surface 124 of core
158 to create first surface 114 of building panel 112, and coating
160 is applied to rear surface 126 of core 158 to create second
surface 116 of building panel 112 as shown. In some embodiments
coating 160 is applied to core 158 and footer 190.
[0090] Building panel 112 in this embodiment has coating 160
applied to two surfaces, front surface 124 and rear surface 126, of
core 158. In some embodiments coating 160 is applied to only one
surface of core 158. In some embodiments coating 160 is applied to
all surfaces of core 158. Coating 160 can be applied to any surface
or portion of core 158 to create building panel 112 according to
the invention.
[0091] In some embodiments of building panel structure 110, core
158 is built and covered with coating 160 to create building panel
112 before being coupled to footer 190. In some embodiments
building panel 112 is made off-site and shipped to the building
site to be coupled to footer 190. In some embodiments building
panel 112 has track 228 (FIG. 18 and FIG. 19) coupled to core 158
to cover a part of one or more than one side 180. Track 228 will be
discussed in detail shortly.
[0092] In the embodiment shown in FIG. 6, building panel 112 is
made in-place on footer 190 as described above. Multiple building
panels 112 can be added to composite building panel structure 110
to create walls, ceilings, floors, beams, bridges, of any other
desired structure. In this embodiment composite building panel 112
forms part of building panel structure 110 which is a wall. In
other embodiments building panel 112 forms parts of other
structures and buildings in accordance with building panel
structure 110. In some embodiments building panel structure 110 is
a building. In other embodiments building panel structure 110 is a
bridge. In some embodiments building panel structure 110 is a
structure. Building panel structure 110 is any building, structure,
or edifice of any shape, size or use which is formed of at least
one building panel according to the invention.
[0093] Building panel structure 110 as shown in FIG. 6 through FIG.
8 is structurally sound as soon as coating 160 dries, and there is
no need for external structural elements to hold building panel 112
in place while the rest of building panel structure 110 is created.
In other types of foam block panel construction, for example, the
foam block walls cannot support themselves until the entire
structure is created and fitted together. The walls need to be
supported by external structural elements during construction.
These external structural elements used to hold the structure
together during construction are not necessary when using building
panel 112 according to the invention. Building panels 112 formed
each day as part of building panel system 110 are structural sound
and secure as soon as coating 160 dries, and each day whatever part
of the complete structure has been completed is strong and secure
and not in danger of collapsing.
[0094] Building panel 112 in this embodiment is stronger than other
types of foam block walls. Core 158 and coating 160 give building
panel structure 110 the strength to both hold building panel 112
secure during construction and withstand strong environmental
elements and forces during the lifetime of the building, such as
wind and earth movement. Building panel 112 is environmentally
friendly, creating an energy efficient structure using recyclable
material with less waste.
[0095] Building panels 112 can be used to form a wall, a floor, a
roof, ceiling or any other part of a building or other building
panel structure 110. Building panel 112 as part of building panel
structure 110 according to the invention can be a complete building
or a part of a building. Building panel 112 as part of building
panel structure 110 can form part of a bridge, a fence, or other
structure.
[0096] FIG. 10 through FIG. 15 show additional embodiments of
elements of building panel 112 and building panel system 110. FIG.
10 and FIG. 11 show horizontal cross-sections of two embodiments of
building panel 112 where core 158 includes wire mesh 272 embedded
in core 158. In this embodiment frame 130 of core 158 includes
vertical frame members 132, which are steel box tube columns in
this embodiment. Wire mesh 272 is stretched between and coupled to
two adjacent vertical frame members 132 as shown in the drawings.
Wire mesh 272 and vertical frame members 132 can be coupled in many
different ways. In the embodiments shown, wire mesh 272 is coupled
to L-bracket 135. L-Bracket 135 is coupled to vertical frame member
132. In this way core 158 includes vertical frame members 132 and
wire mesh 272, where wire mesh 272 is coupled to two adjacent
vertical frame members 132. In this way core 158 includes vertical
frame members 132 and wire mesh 272, where wire mesh 272 is
stretched between two adjacent vertical frame members 132. Blocks
140 are cut to shape and placed around vertical frame members 132
and wire mesh 272. Vertical frame members 132 and wire mesh 272 are
covered with blocks 140. In this way core 158 includes wire mesh
272 embedded in blocks 140 of core 158. Wire mesh 272 can be
coupled to L-bracket 135 in many different ways. In FIG. 10 wire
mesh 272 is coupled to L-bracket 135 using screw 137. L-bracket 135
is coupled to vertical frame member 132 by welding. In FIG. 11 wire
mesh 272 is coupled to L-bracket 135 using hooks 138. L-bracket 135
is coupled to vertical frame member 132 using screw 137. In some
embodiments wire mesh 272 is coupled to vertical frame members 132
using other coupling means. In some embodiments wire mesh 272 is
chain-link fence. Wire mesh 272 adds structural strength to
building panel 112.
[0097] FIG. 12 shows an embodiment of building panel 112 where
C-channel 136 is embedded in block tongue 152 of core 158. FIG. 12
shows a vertical cross-section of an embodiment of building panel
112, showing core 158, coating 160, and block 140 of core 158
interlocking using interlock elements 150 which include block
groove 154 and block tongue 152. C-channel 136 is embedded in block
tongue 152. This provides additional strength to blocks 140, core
158, and building panel 112. Block tongue 152 is strengthened and
protected by C-channel 136. This creates a stronger connection
between the two blocks 140, which further strengthens core 158. In
this way core 158 of building panel 112 includes C-channel 136
embedded in block tongue 152.
[0098] FIG. 13 shows an embodiment of building panel structure 110
illustrating an alternate embodiment of footer tongue 194 and
building panel tongue 154. In this embodiment of building panel
structure 110, building panel 112 includes building panel tongue
154. Footer 190 includes footer tongue 194. Building panel tongue
154 interlocks with footer tongue 194 to couple building panel 112
to footer 190. Coating 160 covers core 158 and footer 190. Coating
160 creates a barrier to prevent moisture from entering between
footer 190 and core 158. But even if moisture should penetrate
coating 160, moisture, water, and elements cannot climb footer
tongue 194. This protects the interior of building panel structure
110 from water, moisture, and the elements.
[0099] FIG. 14 and FIG. 15 show embodiments of building panel 112
where building panel 112 includes control joint 142. Control joint
142 is used to control and prevent cracking of coating 160. Control
joints 142 can be included anywhere on building panel 112,
including on any surface and running in any direction. Control
joint 142 is often placed at areas of stress in building panel 112
or coating 160, where cracking is likely to occur, such as at
window corners, or where two walls meet or where two blocks 140
meet. Control joint 142 includes notch 141 cut in core 158 and
control joint reinforcement mesh 144. Control joint 142 includes
control joint reinforcement mesh 144 to inhibit cracking of coating
160. Notch 141 acts to direct any cracking that does occur in a
particular predetermined direction. Control joint reinforcement
mesh 144 is a metal mesh in some embodiments. In some embodiments
control joint reinforcement mesh 144 is a fiberglass mesh. In some
embodiments control joint reinforcement mesh 144 is made of other
materials. Control joint 142 is created by cutting notch 141 in
insulating structural block 140 of core 158 and applying control
joint reinforcement mesh 144 in coating 160 at control joint 142.
FIG. 14 shows an embodiment of building panel 112 where control
joint 142 according to the invention includes a triangular-shaped
notch 141 in building panel 112. In this embodiment control joint
reinforcement mesh 144 is embedded in brown mixture 168 of coating
160 while brown mixture 168 is still wet, similar to the
application of fiberglass mesh 170 in coating 160. Control joint
reinforcement mesh 144 covers notch 141 and often covers several
inches on either side of notch 141. In a specific embodiment
control joint reinforcement mesh 144 runs six inches on either side
of notch 141. Control joint reinforcement mesh 144 strengthens
coating 160 at control joint 142, inhibiting cracks in coating 160
which can be unsightly and can allow moisture and elements into
building panel 112. In this way building panel 112 includes control
joint 142, where control joint 142 includes notch 141 and control
joint reinforcement mesh 144.
[0100] FIG. 15 shows an embodiment of building panel 112 with
control joint 142 according to the invention, where control joint
142 includes square notch 141 in building panel 112, and backer rod
232 and sealant 234. In this embodiment of control joint 142
according to the invention, control joint reinforcement mesh 144 is
embedded in brown mixture 168 of coating 160 at notch 141 while
brown mixture 168 is still wet, similar to the application of
fiberglass mesh 170 in brown mixture 168. After coating 160 has
cured, backer rod 232 and sealant 234 is used to fill in notch 141
of control joint 142. This embodiment of control joint 142 creates
a flat surface on building panel 112 once finish coatings are
applied. In this way building panel 112 includes control joint 142,
where control joint 142 includes notch 141, control joint
reinforcement mesh 144, backer rod 232, and sealant 234.
[0101] Building panel structure 110 according to the invention
includes building panels with cores and coatings of many different
types. FIG. 16 through FIG. 21 show an additional embodiment of a
building panel according to the invention. FIG. 16 is a perspective
view of building panel 212 according to the invention. FIG. 17 is a
perspective view of core 258 of building panel 212 of FIG. 16. FIG.
18 is an end view and FIG. 19 a perspective view of track 228 used
with building panel 212 of FIG. 16. FIG. 20 is a horizontal cross
section, and FIG. 21 a vertical cross section, of building panel
212 of FIG. 16 using core 258, track 228, and coating 260.
[0102] Building panel 212 according to the invention includes core
258 and track 228 covering a portion of an edge of core 258.
Building panel 212 as shown in the embodiment of FIG. 16 has first
surface 214, second surface 216, and four edges 180 covered by
tracks 228. In this embodiment first surface 214 is an interior
surface and includes wallboard 242. Wallboard 242 is made of sheet
rock in this embodiment. In this embodiment second surface 216 is
an exterior surface which includes coating 260. In some embodiments
of building panel 212, both first surface 214 and second surface
216 include coating 260.
[0103] FIG. 17 shows a perspective view of core 258 as used with
building panel 212 of FIG. 16. Core 258 uses frame 230 which has a
"square serpentine" shape as shown in FIG. 17 and FIG. 20, with
rectangles of insulating structural block 240 filling in the space
within frame 230 squares. Frame 230 is galvanized steel in this
embodiment. In some embodiments frame 230 is other types of metal.
In other embodiments frame 230 can be formed from other structural
materials such as wood, plastic, or an equivalent material. In this
embodiment insulating structural blocks 240 are EPS foam blocks,
one pound density. Other materials and densities can be used for
blocks 240. Core 258 is an example of one type of core that can be
used to create building panel 212. Other shapes and sizes of frame
230 and blocks 240 can be used to form core 258 of building panel
212 according to the needs of the building.
[0104] Core 258 in the embodiment shown in FIG. 17 has front
surface 176 which in this embodiment is covered with wallboard 242
to create first surface 214 of building panel 212. Core 258 in this
embodiment has rear surface 178 which in this embodiment is covered
with coating 260 to create second surface 216 of building panel
212. Core 258 has four edges 180 in this embodiment. In this
embodiment edges 180 are covered with tracks 228. In this way core
258 has front surface 176, rear surface 178, and at least one edge
180 covered with track 228. In this way core 258 has front surface
176, rear surface 178, sides 180, and tracks 228 coupled to core
258. Core 258 according to the invention can have any number, size,
and shape of surfaces, where `surface` includes both sides and
edges. In this embodiment of building panel 212 a portion of one or
more than one of the surfaces of core 258 is covered with coating
260. In some embodiments coating 260 is applied to a both front
surface 176 and rear surface 178. In some embodiments other
coatings are applied to front surface 176 or rear surface 178. In
some embodiments of building panel 212 a portion of one or more
than one of the surfaces of core 258 of building panel 212 is
covered with coating 160 as discussed earlier. In some embodiments
of building panel 212 a portion of one or more than one of the
surfaces of core 258 of building panel 212 is covered with a
different coating. Core 258 can have a coating applied to a portion
of any surface, such as coating 260, coating 160, coating 360
(discussed later) or another coating according to the invention.
These coatings protect the surfaces of core 258 and building panel
212, provide strength to building panel 212, keep elements,
weather, and moisture from permeating building panel 212, and
provide a smooth, aesthetically pleasing surface for applying any
desired finish coatings. Coating 260 will be further discussed
shortly.
[0105] Building panel 212 includes core 258, and track 228 coupled
to core 258. FIG. 18 and FIG. 19 show the details of this
embodiment of track 228. Track 228 has many uses. Track 228
protects the edge surfaces of core 258 that it covers, provides a
means to couple building panel 212 with other building panels and
other structures, supplies a screed edge for applying a
predetermined thickness of coating on core 258, and provides a
means for moisture and water that permeate building panel 212 to
exit building panel 212.
[0106] Track 228 includes base portion 220, where base portion 220
covers a portion of edge 180 of core 258. In this embodiment tracks
228 are coupled to each of the four edge surfaces 180 of core 258
as shown in FIG. 16. FIG. 20, and FIG. 21. In this embodiment base
portion 220 of tracks 228 covers all four edge surfaces 180 of core
258. In some embodiments base portions 220 of track 228 covers some
but not all of the edge surfaces 180 of core 258. Base portion 220
of track 228 according to the invention covers at least a portion
of one edge 180 of core 258. In this way building panel 212
includes core 258 with a front surface 176, rear surface 178, edge
180, and track 228 coupled to core 258. Track 228 includes base
portion 220 covering a portion of edge 180.
[0107] Base portion 220 of track 228 includes rain drain channel
250, as shown in FIG. 18 and FIG. 19. Rain drain channel 250
collects moisture and water which may permeate into the interior of
building panel 212 and directs it to weep holes which allow the
moisture to exit building panel 212. In this way rain drain
channels 250 keep building panel 212 free from internal moisture
buildup which can cause rot, mold or degradation of building panel
212. In this way base portion 220 of track 228 includes rain drain
channel 250.
[0108] Track 228 in this embodiment includes first opposing arm 226
and second opposing arm 227. Core 258 slips between first and
second opposing arms 226 and 227. First and second opposing arms
226 and 227 couple track 228 to core 258 while building panel 212
is being formed. In some embodiments first opposing arm 226 and
second opposing arm 227 frictionably engage front surface 176 and
rear surface 178, respectively, of core 258. In this way track 228
includes first opposing arm 226 and second opposing arm 227. In
some embodiments track 228 does not include first opposing arm 226
and second opposing arm 227.
[0109] Track 228 in this embodiment includes seal spacer channel
222. Seal spacer channel 222 is used to contain seal 244 when two
building panels 212 are being coupled together at their respective
tracks 228 as shown in FIG. 22. Seal 244 provides a flexible,
water- and air-tight seal between two building panels 212. In this
way building panel 212 includes track 228, where track 228 includes
seal spacer channel 222.
[0110] Track 228 in the embodiment shown includes screed boundaries
224. Screed boundaries 224 are used as a screed reference when a
coating such as coating 260 or coating 160 is being applied to core
258. Coating 260 in this embodiment is trowelled onto second
surface 178 and leveled off using screed boundary 224. In this way
screed boundary 224 is used to create coating 260 with a flat level
surface, where the surface is defined by screed boundary 224. In
this way building panel 212 includes track 228, where track 228
includes screed boundaries 224. In some embodiments of track 228
only one screed boundary 224 is included in track 228. In some
embodiments track 228 does not include any screed boundaries
224.
[0111] FIG. 20 is a horizontal cross-section of building panel 212
taken at section 20-20 of FIG. 16, and FIG. 21 is a vertical
cross-section of building panel 212 taken at section 21-21 of FIG.
16. Tracks 228 are coupled to ends 180 of core 258. Front surface
176 of core 258 is covered with wallboard 242 to create first
surface 214 of building panel 212. In this embodiment wallboard 242
is a 5/8'' wallboard. First surface 214 of building panel 212 is
used in this embodiment for interior walls and can have an interior
finish applied such as tape, plaster, and/or paint. In some
embodiments other finishes are used.
[0112] Rear surface 178 of core 258 has coating 260 applied to it
to create second surface 216 of building panel 212. Coating 260 in
this embodiment includes a layer of wire mesh 272, covered by brown
mixture 168 and fiberglass mesh 170 embedded in brown mixture 168.
Brown mixture 168 is a cementitious mixture made of cement,
aggregate, acrylic bonder, and fiberglass strands, as discussed
earlier with regard to coating 160. Wire mesh 272 in this
embodiment is a 9 gage concrete wire mesh. Fiberglass mesh 170 is
embedded in brown mixture 168 while brown mixture 168 is still wet,
as previously discussed in regard to coating 160. Coating 260 can
be finished with any desired finish coating including an
elastomeric, cementitious, or acrylic finish coat, depending on the
usage of building panel 212. Brown mixture 168 has the same
components and optional components as discussed earlier with regard
to coating 160.
[0113] Building panel 212 is fabricated by forming core 258 from
frame 230 and block 240, coupling tracks 228 to core 258, applying
wallboard 242 to front surface 176 of core 258 to create first
surface 214 of building panel 212, and applying coating 260 to rear
surface 178 of core 258 to create second surface 216 of building
panel 212. Building panel 212 in some embodiments is coupled to
other building panels or other structures to create building panel
structure 110.
[0114] Building panel 212 is light, durable, environmentally
friendly, strong, energy efficient and configurable. Building panel
212 is often used for walls and other structures of commercial
buildings. Frame 230 and coating 260 provide strength to building
panel 212. Insulating structural EPS foam blocks 240 provide energy
efficiency with a material that uses renewable resources. In some
embodiments coating 260 is applied to both sides of building panel
212. In some embodiments other coatings are used on one or both
sides of building panel 212. Building panel 212 can be formed in
any size and shape to create the desired size and shape building,
structure, edifice, beam, fence, etc. Utility and access holes are
cut into or through building panel 212 as needed. Building panel
212 in this embodiment is pre-fabricated and shipped assembled to
the construction site. In some embodiments building panel 212 is
fabricated at the construction site.
[0115] FIG. 22 and FIG. 23 illustrate examples of how building
panels 212 can be coupled to each other and to other structures.
FIG. 22 shows a cross-section of two building panels 212 connected
track-to-track according to the invention. FIG. 23 shows a
cross-section of building panel 212 connected to concrete
foundation 192 according to the invention. FIG. 22 shows two
building panels 212 connected end-to-end by butting tracks 228
together, with rubber seal spacer 244 and backer rods 232 in
between as shown. Seal spacer 244 is placed between the two
adjacent seal spacer channels 222 and provides a flexible sealant
between the two tracks 228. Backer rods 232 provide the spacing for
each end of the tracks 228. Sealant 234 is used to fill the air
spaces between the two tracks 228. In this embodiment caulk is used
as sealant 234. In some embodiments sealants other than caulk are
used as sealant 234, depending on the use of the structure. Rain
drain channels 250 collect and drain moisture between the two
building panels 212. In this way any water, moisture, or other
fluids which happen to penetrate into the interior of building
panel 212 is removed so that corrosion and rot will not occur.
[0116] FIG. 23 shows building panel 212 coupled to concrete
foundation 192. In some embodiments building panel 212 is coupled
to concrete footer 190. In the embodiment shown, bituthane seal 238
is applied to concrete foundation 192, followed by drip flashing
236. Track 228 is placed over drip flashing 236, with backer rods
232 in between. Anchor bolt 294 is used to mechanically couple
building panel 212 to concrete foundation 192. In this embodiment
nut, spacer, and washer 296 is used to connect to anchor bolt 294.
Sealant 234 is used to fill in air spaces and seal the connection.
Rain drain channels 250 collect and direct moisture and water to
weep holes where it is allowed to escape.
[0117] FIG. 24 through FIG. 27 illustrate another embodiment of a
building panel according to the invention. FIG. 24 shows a
perspective view of building panel 312 according to the invention.
FIG. 25 shows a perspective view of core 358 of building panel 312
of FIG. 24. FIG. 26 is a horizontal cross-section, and FIG. 27 a
vertical cross section, of building panel 312 of FIG. 24. Building
panel 312 uses access channels 280 to provide access to frame 330
of building panel 312 according to the invention. Access to frame
330 can be used for many purposes. In some embodiments access to
frame 330 is used to interconnect building panel 312 to other
structures such as floors, walls, or other building panels.
[0118] Building panel 312 includes core 358 and coating 360, where
coating 360 covers a portion of core 358. Building panel 312 has
tracks 228 covering the edges of core 358. Building panel 312 has
first surface 314 which includes wallboard 242, and second surface
316, where second surface 316 includes coating 360.
[0119] Core 358 uses frame 330 in a square serpentine shape, with
thicker insulting structural blocks 340 used on one side of core
358 than the other side, as shown in FIG. 25 and FIG. 26. Core 358
has front surface 374 and rear surface 376. In this embodiment
insulating structural blocks 340 are thicker on rear surface 376 of
core 358 than they are on front surface 374 of core 358. Blocks 340
are held to frame 330 in this embodiment with screws 256 and
pressure spreaders 254. Pressure spreader 254 (one of several
labeled) distributes the pressure of screw 256 (one of several
labeled) over an area of block 340, allowing pressure spreader 256
to grab onto block 340 and hold it to frame 330. Without pressure
spreader 254, screw 256 may make a hole in insulating structural
block 340 instead of holding block 340 to frame 330. In this
embodiment screw 256 and pressure spreader 254 are from Wind-lock
company.
[0120] FIG. 26 is a horizontal cross-section of building panel 312
taken at section 26-26 of FIG. 24. FIG. 27 is a vertical
cross-section of building panel 312 taken at section 27-27 of FIG.
24. First surface 314 in this embodiment of composite building
panel 312 has wallboard 242 coupled to front surface 374 of core
358. Second surface 316 of building panel 312 has coating 360
covering rear surface 376 of core 358. Coating 360 in this
embodiment is a "synthetic stucco" finish, which in this embodiment
is an Exterior Insulation and Finish System (EIFS) coating. In this
embodiment coating 360 is made of fiberglass mesh 170 embedded into
polymer-based adhesive 274 such as Primus manufactured by Dryvit.
Finish coatings can be applied to wallboard 242 and coating 360. It
should be understood that in some embodiments coating 160 as
described earlier can be applied to front surface 374 and/or rear
surface 376 of core 358. In some embodiments of composite building
panel 312 first side 314 and/or second side 316 include coating
160. It should be understood that in some embodiments coating 260
as described earlier can be applied to front surface 374 and/or
rear surface 376 of core 358. In some embodiments of composite
building panel 312 first side 314 and/or second side 316 include
coating 260. In some embodiments of building panel 312 coating 160,
coating 260, or other coatings are applied to a portion of core 358
to create building panel 312.
[0121] In the embodiment of building panel 312 shown in FIG. 24
through FIG. 27, both core 358 and coating 360 provided strength
and stability to building panel 312. Building panel 312 can be used
for many building applications, for example but not by way of
limitation, commercial or residential building applications.
Building panel 312 provides superior energy efficiency with
lightweight, high-strength building panels 312. Any moisture or
water that permeates building panel 312 will be routed horizontally
and vertically through rain drain channels 250 of track 228 to weep
holes where they exit the structure.
[0122] Access channels 280 are used to terminate and seal wallboard
242 at opening 284, where opening 284 in this embodiment is for a
floor structure to connect to frame 330. In this embodiment access
channels 280 are 2''.times.2'' galvanized steel channel, which can
be welded or bolted to frame 330. This leaves opening 284, where
wallboard 242 does not cover frame 330 and blocks 340. In this
embodiment opening 284 is 12'' in height, and allows a floor
structure to be connected to frame 330. In some embodiments opening
284 is used to couple other structural elements to frame 330,
depending on the specific design and structure that is being built.
In some embodiments opening 284 is other shapes or sizes to
accommodate connections to different structural elements or to
other building panels, such as but not limited to building panels
112, 212, or 312. In this way building panel 312 includes opening
284, where opening 284 allows access to frame 330.
[0123] The specific embodiments of composite building panels 112,
212, and 312 and building panel structure 110 provided in this
document should not be considered exhaustive. The disclosed parts
and layers can be used interchangeably as needed to create desired
structures and edifices according to the invention. Building panels
of any size, thickness, shape, and strength can be created by
interchanging the various components disclosed. It is to be
understood that the cores and coatings and tracks described in this
document can be used interchangeably to construct building panel
structure 110 according to the invention.
[0124] FIG. 28 illustrates method 400 of forming a building panel
structure according to the invention. Method 400 includes step 402
forming a core using a frame and one or more than one insulating
structural block. Method 400 also includes step 404, applying an
inner scratch layer to a portion of the core. Method 400 includes
step 406, applying an outer main brown layer over the scratch
layer, wherein the outer main brown layer includes cement,
aggregate, acrylic bonder, fiberglass strands, and fiberglass
mesh.
[0125] Method 400 can include many other steps. In some embodiments
method 400 includes pouring a footer with an integral footer
tongue, and coupling the core to the footer tongue, wherein the
core includes a building panel groove. In some embodiments method
400 includes coupling a track to the core, where the track includes
a rain drain channel. In some embodiments method 400 include
interconnecting multiple building panels. In some embodiments
method 400 includes interconnecting a building panel to a
foundation using interconnect elements. In some embodiments
interconnecting multiple building panels includes interconnecting
multiple building panels by interconnecting the tracks of two or
more building panels. In some embodiments interconnecting a
building panel to a foundation includes interconnecting a building
panel track to a foundation.
[0126] Step 402 forming a core using a frame and one or more than
one insulating structural block can include many other steps. In
some embodiments forming a core using a frame and one or more than
one insulating structural block means embedding the frame within
the one or more than one insulating structural block. In some
embodiments the one or more than one block are composed of expanded
polystyrene foam. In some embodiments step 402 includes cutting an
insulating structural block to shape. In some embodiments step 402
include erecting structural members. In some embodiments step 402
includes stretching a wire mesh between two structural members. In
some embodiments step 402 includes forming a structural element
from galvanized steel. In some embodiments step 402 includes
interconnecting a block and a frame using interconnect elements. In
some embodiments step 402 includes coupling a C-channel to the
tongue interconnect element of a block. In some embodiments step
402 includes cutting utility access routes into a frame or a block.
In some embodiments step 402 include cutting control joint notches
into a block.
[0127] Step 404 applying an inner scratch layer to a portion of the
core can include many other steps. In some embodiments step 404
includes applying an acrylic modified cementitious membrane to the
core. In some embodiments the scratch layer comprises two layers.
In some embodiments the scratch layer includes a first scratch
layer A and a second scratch layer B. In some embodiments applying
an inner scratch layer to a portion of the core includes creating a
first scratch layer A mixture comprising cement, aggregate, acrylic
bonder, and water. In some embodiments applying an inner scratch
layer to a portion of the core includes blowing the first scratch
layer A mixture onto a portion of the core. In some embodiments
applying an inner scratch layer to a portion of the core includes
allowing the first scratch layer A mixture to cure. In some
embodiments applying an inner scratch layer to a portion of the
core includes creating a second scratch layer B brown mixture
comprising cement, aggregate, acrylic bonder, fiberglass strands,
and water. In some embodiments applying an inner scratch layer to a
portion of the core includes trowelling the second scratch layer B
brown mixture over the first scratch layer A. In some embodiments
applying an inner scratch layer to a portion of the core includes
embedding a fiberglass mesh in the second scratch layer B brown
mixture while the second scratch layer B brown mixture is still
wet. In some embodiments applying an inner scratch layer to a
portion of the core includes allowing the second scratch layer B
brown mixture to cure. In some embodiments the second scratch layer
B brown mixture aggregate includes sand. In some embodiments the
second scratch layer B brown mixture aggregate includes 20 grit
sand and 30 grit sand. In some embodiments the second scratch layer
B brown mixture aggregate includes perlite. In some embodiments the
second scratch layer B brown mixture aggregate includes
vermiculite. In some embodiments the inner scratch layer is 1/8''
thick. In some embodiments applying an inner scratch layer includes
embedding a wire mesh in the first scratch layer A. In some
embodiments applying an inner scratch layer includes embedding a
wire mesh in the second scratch layer B. In some embodiments the
wire mesh is a 9 gage concrete wire mesh.
[0128] Step 406 applying an outer main brown layer over the inner
scratch layer can include many other steps. In some embodiments
step 406 includes applying a wire mesh over the inner scratch
layer. In some embodiments applying an outer main brown layer over
the inner scratch layer includes creating a main brown layer brown
mixture comprising cement, aggregate, acrylic bonder, fiberglass
strands, and water. In some embodiments applying an outer main
brown layer over the inner scratch layer includes trowelling the
main brown layer brown mixture over the inner scratch layer. In
some embodiments applying an outer main brown layer over the inner
scratch layer includes embedding a fiberglass mesh into the main
brown layer brown mixture while the main brown layer brown mixture
is still wet. In some embodiments applying an outer main brown
layer over the inner scratch layer includes allowing the main brown
layer brown mixture to cure. In some embodiments the main brown
layer brown mixture aggregate includes sand. In some embodiments
the main brown layer brown mixture aggregate includes two types of
sand. In some embodiments the main brown layer brown mixture
aggregate includes 20 grit sand and 30 grit sand. In some
embodiments the main brown layer brown mixture aggregate includes
perlite. In some embodiments the main brown layer brown mixture
aggregate includes vermiculite. In some embodiments the main brown
layer brown mixture includes other components. In some embodiments
applying an outer main brown layer over the inner scratch layer
includes trowelling the main brown layer over the scratch layer
such that the outer main brown layer is 1/4'' thick. In some
embodiments applying an outer main brown layer over the inner
scratch layer includes embedding a control joint reinforcement mesh
in the main brown layer brown mixture over a control joint notch
while the main brown layer brown mixture is still wet.
[0129] FIG. 29 illustrates a method 440 of forming a structure
which includes step 442 forming a building panel, step 444 coupling
a track to the building panel, wherein the track comprises a rain
drain channel, and step 446 interconnecting multiple building
panels to create a structure.
[0130] Method 440 can include many other steps. In some embodiments
method 440 includes coupling a building panel with a track to a
footer.
[0131] Step 442 forming a building panel can include many other
steps. In some embodiments step 442 forming a building panel
includes forming a core with a frame and one or more than one
insulating structural block, and applying a coating to a portion of
the core. In some embodiments applying a coating to a portion of
the core includes applying a main brown layer to a portion of the
core, where the main brown layer is composed of cement, aggregate,
acrylic bonder, and fiberglass strands. In some embodiments
applying a coating to a portion of the core includes embedding a
fiberglass mesh in the main brown layer while the main brown layer
is still wet. In some embodiments the main brown layer includes a
wire mesh. In some embodiments applying a coating to a portion of
the core includes applying a scratch layer to a portion of the
core. In some embodiments the scratch layer includes a wire mesh.
In some embodiments the scratch layer includes two layers. In some
embodiments applying a scratch layer to a portion of the core
includes applying a first scratch layer A to a portion of the core.
In some embodiments the first scratch layer A is blown onto the
core. In some embodiments the first scratch layer A includes
cement, aggregate, and acrylic bonder. In some embodiments applying
a scratch layer to a portion of the core includes applying a second
scratch layer B over the first scratch layer A. In some embodiments
the second scratch layer B includes cement, aggregate, acrylic
bonder, and fiberglass strands. In some embodiments the second
scratch layer B further includes a fiberglass mesh. In some
embodiments the fiberglass mesh is embedded in the second scratch
layer B while the second scratch layer B is still wet.
[0132] Step 444 coupling a track to the building panel can include
many other steps. In some embodiments coupling a track to the
building panel includes coupling a first and a second opposing arm
of the track to a core. In some embodiments the first and second
opposing arm of the core frictionably engages a front surface and a
rear surface, respectively, of the core. In some embodiments of
step 444 the track includes a seal spacer channel. In some
embodiments of step 444 the track includes a screed boundary.
[0133] Step 446 interconnecting multiple building panels to create
a structure can include many other steps. In some embodiments step
446 includes coupling the track of a first building panel to the
track of a second building panel. In some embodiments step 446
includes coupling a building panel to a footer. In some embodiments
step 446 includes coupling a building panel groove to a footer
tongue. In some embodiments step 446 includes coupling a building
panel to a floor using an opening in the building panel, wherein
the opening allows access to a frame element. In some embodiments
of step 446 building panels are interconnected to form walls. In
some embodiments building panels are interconnected to form roofs.
In some embodiments building panels are interconnected such that
water is directed through rain drain channels to exit the
structure. In some embodiments building panels are interconnected
such that a core is connected to a foundation. In some embodiments
building panels are interconnected such that a core is connected to
a footer.
[0134] The embodiments and examples set forth herein were presented
in order to best explain the present invention and its practical
application and to thereby enable those of ordinary skill in the
art to make and use the invention. However, those of ordinary skill
in the art will recognize that the foregoing description and
examples have been presented for the purposes of illustration and
example only. The description as set forth is not intended to be
exhaustive or to limit the invention to the precise form disclosed.
Many modifications and variations are possible in light of the
teachings above without departing from the spirit and scope of the
forthcoming claims.
* * * * *